Component verification method and component verification system

ABSTRACT

A component verification method includes a component ID reading process of reading a component ID corresponding to a stored component of a subsequent tape, a tape insertion detecting process of detecting that the subsequent tape has been inserted into a tape feeder, a feeder specifying process of specifying a tape feeder in which the insertion of the subsequent tape has been detected, a component verifying process of verifying whether or not a correspondence relationship between the read component ID and the specified tape feeder is correct, and a re-verification requesting process of requesting re-execution of the verification to a worker if it is detected that the subsequent tape has fallen from the tape feeder after the component verifying process.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present disclosure relates to the subject matters contained inJapanese Patent Application No. 2014-012040 filed on Jan. 27, 2014,which are incorporated herein by reference in its entirety.

FIELD

One or more embodiments of the present invention relate to a componentverification method and a component verification system that verifywhether or not stored components of a subsequent tape subsequentlyinserted into a component mounting apparatus for component replenishmentis correct.

BACKGROUND

Tape feeders are known as component supply devices in component mountingapparatuses. The tape feeders pitch-feed carrier tapes holdingelectronic components, thereby supplying the electronic components tocomponent suction positions taken by a mounting head. As a method ofcontinuing component supply continuously without stopping a mountingoperation in the tape feeders, the tape splicing of connecting a newsubsequent carrier tape (subsequent tape) to a trailing end portion of apreceding carrier tape (preceding tape) that is already mounted has beenused in the related art. In this tape splicing method, a worker needs toexecute complicated tape splicing work for every tape replenishment, andit is desired to reduce this workload. For this reason, a splicinglesstype tape feeder in which a subsequent tape is set at the tape feederwithout performing the tape splicing work is used as a new tapereplenishment method (for example, refer to below-described PatentDocument 1).

In the related art shown in Patent Document 1, there is used aconfiguration in which component feed drive units each configured todrive a sprocket with a drive motor are respectively arranged at a tapeinsertion unit provided at a rear end portion of the tape feeder and apickup unit that sends a carrier tape to component pickup positions, andthe preceding tape and the subsequent tape are individually moved. Byvirtue of this configuration, tape supply is performed withoutconnecting the preceding tape and the subsequent tape.

Patent Document 1 is JP-A-2011-211169.

SUMMARY

However, in the related art including the example of the above-describedPatent Document, there is a difficulty in that the followingmalfunctions occur when a carrier tape is continuously supplied to thetape feeder by the splicingless method. Namely, in the splicinglessmethod, the preceding tape and the subsequent tape are not connectedintegrally with each other. Therefore, if an external force is exertedon the subsequent tape due to the worker's unsuitable operation afterthe mounting of the subsequent tape, there is a case where a malfunctionin which the subsequent tape in the mounted state falls from thesprocket occurs.

In such a case, the worker performs the work of making an access to thecomponent supply unit and re-mounting the tape feeder from which thesubsequent tape has fallen. However, since a number of tape feedershaving the same shape are arranged adjacent to each other in thecomponent supply unit, a work error in which the worker erroneouslymounts the subsequent tape on an adjacent tape feeder in thisre-mounting work may occur. In the related art, there is no technique ofdetecting such a work error caused by a worker's carelessness. If thework continues as it is, incorrect components may be supplied andmalfunctions, such as an apparatus stop and a mounting error, may occur.

Thus, an object of the embodiments of the invention is to provide acomponent verification method and a component verification system thatcan prevent malfunctions resulting from a work error in re-mounting of afallen subsequent tape.

According to the embodiments of the invention, there is provided acomponent verification method for verifying whether or not a storedcomponent of a subsequent tape subsequently inserted into a tape feeder,in a state where a preceding tape precedingly sent out of two carriertapes sequentially sent one after another is mounted, for componentreplenishment is correct, in a component mounting apparatus that picksup components, which are supplied from carrier tapes tape-fed by aplurality of tape feeders arrayed in a component supply unit, by amounting head to mount the components on a substrate, the componentverification method including: a component ID reading process of readinga component ID corresponding to the stored component of the subsequenttape; a tape insertion detecting process of detecting that thesubsequent tape has been inserted into the tape feeder; a feederspecifying process of specifying a tape feeder in which the insertion ofthe subsequent tape has been detected; a component verifying process ofverifying whether or not a correspondence relationship between the readcomponent ID and the specified tape feeder is correct; and are-verification requesting process of requesting re-execution of theverification to a worker if it is detected that the subsequent tape hasfallen from the tape feeder after the component verifying process.

According to the embodiments of the invention, there is provided acomponent verification system for verifying whether or not storedcomponents of a subsequent tape subsequently inserted into a tapefeeder, in a state where a preceding tape precedingly sent out of twocarrier tapes sequentially sent one after another is mounted, forcomponent replenishment is correct, in a component mounting apparatusthat picks up components, which are supplied from carrier tapes tape-fedby a plurality of tape feeders arrayed in a component supply unit, by amounting head to mount the components on a substrate, the componentverification system including: a component ID reading unit that reads acomponent ID corresponding to the stored component of the subsequenttape; a tape insertion detecting unit that detects that the subsequenttape has been inserted into the tape feeder; a feeder specifying unitthat specifies a tape feeder in which the insertion of the subsequenttape has been detected; a component verifying unit that verifies whetheror not a correspondence relationship between the read component ID andthe specified tape feeder is correct; and a re-verification requestingunit that requests re-execution of the verification to a worker if it isdetected that the subsequent tape has fallen from the tape feeder afterthe verification.

According to the embodiments, malfunctions resulting from a work errorin re-mounting of a fallen subsequent tape can be prevented.

BRIEF DESCRIPTION OF THE DRAWINGS

A general configuration that implements the various features of theinvention will be described with reference to the drawings. The drawingsand the associated descriptions are provided to illustrate embodimentsof the invention and should not limit the scope of the invention.

FIG. 1 is a plan view of a component mounting apparatus of an embodimentof the invention.

FIG. 2 is a partial cross-sectional view of the component mountingapparatus of the embodiment of the invention.

FIG. 3 is a configuration explanatory view of a tape feeder of theembodiment of the invention.

FIGS. 4A to 4D are functional explanatory views of a sprocket used for atape feed mechanism in the tape feeder of the embodiment of theinvention.

FIG. 5 is an explanatory view of component ID reading in the tape feederof the embodiment of the invention.

FIGS. 6A and 6B are block diagrams illustrating the configuration of acontrol system of a component verification system of the embodiment ofthe invention.

FIGS. 7A to 7C are explanatory views of tape insertion detection andfalling determination in the tape feeder of the embodiment of theinvention.

FIGS. 8A to 8C are process explanatory views of a tape feed method inthe tape feeder of the embodiment of the invention.

FIGS. 9A to 9C are process explanatory views of the tape feed method inthe tape feeder of the embodiment of the invention.

FIG. 10 is a flow chart illustrating component verification processingby a component verification system of the embodiment of the invention.

FIG. 11 is a flow chart illustrating component verification processingby the component verification system of the embodiment of the invention.

FIGS. 12A to 12C are explanatory views of a notification screen in thecomponent verification processing by the component verification systemof the embodiment of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Next, an embodiment of the invention will be described with reference tothe drawings. First, the configuration of a component mounting apparatus1 that mounts electronic components on a substrate will be describedwith reference to FIGS. 1 and 2. The component mounting apparatus 1 hasa function of mounting electronic components, such as semiconductorchips, on the substrate, and FIG. 2 partially illustrates an A-A crosssection in FIG. 1.

In FIG. 1, a substrate conveying mechanism 2 is disposed in an Xdirection (substrate conveying direction) at the center of a base 1 a.The substrate conveying mechanism 2 conveys a substrate 3 carried infrom the upstream side, and positions and holds the substrate on amounting stage set in order to execute component mounting work.Component supply units 4 are arranged on both lateral sides of thesubstrate conveying mechanism 2, and a plurality of tape feeders 5 aremounted in parallel on each component supply unit 4. The tape feeder 5pitch-feeds a carrier tape, which has stored electronic components, in atape feed direction, that is, in a direction directed to the substrateconveying mechanism 2 from the outside of the component supply unit 4,thereby supplying the electronic components to component suctionpositions taken by a mounting head of a component mounting mechanism tobe described below.

A Y-axis movable table 7 including a linear driving mechanism isdisposed in a Y direction orthogonal to an X direction at an end portionon one side in the X direction on an upper surface of the base 1 a, andtwo X-axis movable tables 8 similarly including linear drivingmechanisms are coupled to the Y-axis movable table 7 so as to be movablein the Y direction. Mounting heads 9 are mounted on the two X-axismovable tables 8, respectively, so as to be movable in the X direction.The mounting head 9 is a multiple head including a plurality of holdingheads, and as illustrated in FIG. 2, suction nozzles 9 a capable ofsuctioning, holding, and individually lifting an electronic componentare mounted on a lower end portion of each holding head.

By driving the Y-axis movable table 7 and the X-axis movable tables 8,the mounting heads 9 move in the X direction and in the Y direction.Accordingly, the two mounting heads 9 suction, hold, and take outelectronic components from the component suction positions of the tapefeeders 5 of the component supply units 4 corresponding thereto,respectively, by the suction nozzles 9 a, and transfer and load theelectronic components to the mounting points of the substrate 3positioned on the substrate conveying mechanism 2. The Y-axis movabletable 7, the X-axis movable table 8, and the mounting head 9 constitutea component mounting mechanism that moves the mounting head 9 holding anelectronic component, thereby transferring and loading the electroniccomponent to the substrate 3.

A component recognition camera 6 is disposed between each componentsupply unit 4 and the substrate conveying mechanism 2. When the mountinghead 9 that has taken out an electronic component from the componentsupply unit 4 moves above the component recognition camera 6, thecomponent recognition camera 6 images and recognizes the electroniccomponent in a state where the electronic component is held by themounting head 9. A substrate recognition camera 11, which is located ona lower surface side of the X-axis movable table 8 and moves integrallywith the mounting head 9, is mounted on the mounting head 9.

As the mounting head 9 moves, the substrate recognition camera 11 movesabove the substrate 3 positioned on the substrate conveying mechanism 2,and images and recognizes the substrate 3. In the component mountingoperation to the substrate 3 performed by the mounting head 9, arecognition result of an electronic component obtained by the componentrecognition camera 6 and a substrate recognition result obtained by thesubstrate recognition camera 11 are considered, and loading positioncorrection is performed. Display units including display screens, suchas liquid crystal panels, are arranged on both side surfaces of thecomponent mounting apparatus 1. An operation screen for operation inputand various notification screens are displayed on each display unit 15.

As illustrated in FIG. 2, a carriage 12 in a state where a plurality oftape feeders 5 is mounted in advance on a feeder base 12 a is set at thecomponent supply unit 4. Feeder addresses for specifying feederpositions where the respective tape feeders 5 are mounted are set in thefeeder base 12 a, and in the component mounting work, the respectivetape feeders 5 in the feeder base 12 a are specified via these feederaddresses.

By clamping a feeder base 12 a to a fixing base 1 b provided in the base1 a with a clamp mechanism 12 b, the position of the carriage 12 isfixed in the component supply unit 4. A supply reel 13 that stores acarrier tape 14 that has held electronic components in a wound state isheld by the carriage 12. The carrier tape 14 pulled out from the supplyreel 13 is pitch-fed to component suction positions taken by the suctionnozzles 9 a by the tape feeder 5.

Next, the configuration and functions of the tape feeder 5 will bedescribed with reference to FIG. 3. As illustrated in FIG. 3, the tapefeeder 5 has a configuration including a body portion 5 a and a mountingportion 5 b provided to protrude downward from a lower surface of thebody portion 5 a. The tape feeder 5 is fixed to and mounted on thecomponent supply unit 4 in a state where the tape feeder 5 is mountedsuch that the lower surface of the body portion 5 a runs along thefeeder base 12 a, and a feeder controller 28 built in to control tapefeed in the tape feeder 5 is electrically connected to an apparatuscontroller 29 of the component mounting apparatus 1.

A tape traveling path 5 c along which the carrier tape 14 is pulled outfrom the supply reel 13 and taken into the body portion 5 a is providedinside the body portion 5 a. The tape traveling path 5 c is provided soas to communicate from a tape introduction port 5 d opening to anupstream end portion in the tape feed direction in the pitch feeding inthe body portion 5 a to component suction positions where electroniccomponents are taken out by the mounting head 9. In the process ofcontinuously executing the component mounting work, a plurality ofcarrier tapes 14 having the amount of a tape to be stored in one supplyreel 13 as a unit lot are sequentially inserted from the tapeintroduction port 5 d and are supplied to the tape feeder 5.

In the component mounting apparatus 1 illustrated in the presentembodiment, there is adopted a splicingless method in which, out of twocarrier tapes 14 that are introduced from the tape introduction port 5 dand sent one after another, a trailing end portion of a carrier tape14(1) (hereinafter abbreviated as a preceding tape 14(1)) that isalready mounted on the tape feeder 5 and serves as a componentextraction target by the mounting head 9 and a leading end portion of acarrier tape 14(2) (hereinafter abbreviated as a subsequent tape 14(2))that is newly added and mounted in the case of a component shortage aresequentially inserted and supplied into the tape introduction ports 5 dwhile remaining separated, respectively, without performing the tapesplicing of joining these tapes together using a joining tape.

A sprocket 21C with which the subsequent tape 14(2) to be additionallymounted is engaged is disposed above the tape introduction port 5 d. Thesprocket 21C has a function of regulating the tape feed direction of thesubsequent tape 14(2), thereby preventing falling of the subsequent tape14(2). A first tape feed mechanism 20A and a second tape feed mechanism20B for feeding the preceding tape 14(1) and the subsequent tape 14(2)are disposed on a downstream side and on an upstream side in the tapetraveling path 5 c.

The second tape feed mechanism 20B provided on the upstream side has afunction of feeding the subsequent tape 14(2) to be newly mountedcontinuously from a tape introduction port 5 d side to a first tape feedmechanism 20A side, and has a configuration in which a sprocket 21B isrotationally driven by a second motor M2. A tape pressing mechanism 24and a tape stopper mechanism 25 are disposed below the second tape feedmechanism 20B. The subsequent tape 14(2) introduced into the tapeintroduction port 5 d via the sprocket 21C is pressed against thesprocket 21B by the tape pressing mechanism 24, and thereby, thesubsequent tape 14(2) is engaged with the sprocket 21B and is broughtinto a state where the tape feed performed by the second tape feedmechanism 20B is allowed. The tape stopper mechanism 25 has a functionof temporarily stopping the leading end portion of the subsequent tape14(2) newly inserted in a state where the preceding tape 14(1) ismounted, by a stopper member 25 a.

The first tape feed mechanism 20A provided on the downstream side has afunction of pitch-feeding the preceding tape 14(1) to the componentsuction positions taken by the mounting head 9 at a predeterminedfeeding pitch, and has a configuration in which a sprocket 21A isrotationally driven by a first motor M1. A pressing member 27 that holdsdown the preceding tape 14(1) from above and exposes a component storedin the preceding tape 14(1) is mounted above the first tape feedmechanism 20A, and electronic components pitch-fed to the componentsuction positions are picked up through vacuum suction by the suctionnozzles 9 a of the mounting head 9 via a component extraction opening 27a formed in the pressing member 27.

Here, the functions of the sprockets 21A, 21B, and 21C will be describedwith reference to FIGS. 4A to 4D. As illustrated in FIG. 4A, a pluralityof feed pins 21 a are provided on outer peripheral surfaces of thesprockets 21A, 21B, and 21C. Feed holes 14 b into which the feed pins 21a are fitted, together with the component pockets 14 a that storeelectronic components serving as supply targets, are formed atpredetermined pitches in the carrier tape 14. As the sprockets 21A and21B rotate in a state where the feed pins 21 a are engaged with the feedholes 14 b, the carrier tape 14 is tape-fed.

FIG. 4B illustrates the function of the sprocket 21C. A one-way clutchmechanism 22 that permits rotation only in a rotational direction (arrowa) corresponding to the tape feed direction from the upstream side tothe downstream side (arrow b) and prohibits rotation in an oppositedirection (arrow c) is built into the sprocket 21C. Accordingly, themovement of the subsequent tape 14(2) in a normal tape feed direction(arrow b) is performed and the movement thereof in an opposite direction(arrow c) is prohibited, in a state where the subsequent tape 14(2) isengaged with the sprocket 21C. Accordingly, even when an external forcein a pulling-out direction is exerted on the subsequent tape 14(2) dueto unsuitable handling or the like of a worker in a state where thesubsequent tape 14(2) is newly mounted for component supply, thesubsequent tape 14(2) is locked by the sprocket 21C, and falling fromthe tape feeder 5 is prevented.

FIG. 4C illustrates the function of the sprocket 21B in the second tapefeed mechanism 20B. As mentioned above, the sprocket 21B is rotationallydriven by the second motor M2, thereby continuously feeding thesubsequent tape 14(2). In this drive method, the idling of the sprocket21B is permitted and the movement of the subsequent tape 14(2) in thestate of being engaged with the sprocket 21B is also permitted, in adeenergized state where the driving of the second motor M2 is not drivecontrolled.

An encoder 23 serving as rotation detecting means is built into thesprocket 21B. If the subsequent tape 14(2) moves in a downstreamdirection (arrow f) and in an upstream direction (arrow g), the sprocket21B rotates in a normal direction (arrow d) and in a reverse direction(arrow e), respectively, and rotation detection signals according tothese rotation states are transmitted to the feeder controller 28. Inthe present embodiment, the state of the subsequent tape 14(2) in thesecond tape feed mechanism 20B is determined by monitoring the rotationdetection signals transmitted to the feeder controller 28.

First, if the rotation of the sprocket 21B in the normal direction(direction of arrow d) is detected, it is determined that a new carriertape 14 has been inserted, and the driving of the second motor M2 fortape feed is started. Accordingly, the inserted carrier tape 14 is sentto the downstream side along the tape traveling path 5 c. Additionally,if the rotation of the sprocket 21B in the reverse direction (directionof arrow e) is detected after the rotation of the sprocket in the normaldirection (direction of arrow d) is detected, it is determined that thecarrier tape 14 that has been previously inserted and engaged with thesprocket 21B has moved in a falling direction (direction of arrow g) dueto a certain cause, and tape falling determination is made.

FIG. 4D illustrates the function of the sprocket 21A in the first tapefeed mechanism 20A. As mentioned above, the sprocket 21A isintermittently driven by the first motor M1, thereby pitch-feeding(arrow h) the preceding tape 14(1) at predetermined feeding pitches.Accordingly, the electronic components stored within the componentpockets 14 a of the carrier tape 14 are supplied to the componentsuction positions taken by the mounting head 9.

A first detection position P1 for detecting the carrier tape 14 is seton the upstream side of the first tape feed mechanism 20A in the tapetraveling path 5 c, and a second detection position P2 for detecting thecarrier tape 14 is similarly set on the downstream side of the secondtape feed mechanism 20B and on the upstream side of the first detectionposition P1. A first sensor S1 and a second sensor S2 disposed at thefirst detection position P1 and the second detection position P2,respectively, detect the presence/absence of the carrier tape 14 at thefirst detection position P1 and the second detection position P2.Moreover, a third sensor S3 that detects that the subsequent tape 14(2)abuts against the stopper member 25 a is disposed at the tape stoppermechanism 25.

The detection results obtained by the first sensor S1, the second sensorS2, and the third sensor S3 are transmitted to the feeder controller 28,and the feeder controller 28 controls the first tape feed mechanism 20Aand the second tape feed mechanism 20B based on these detection resultsand the rotation detection result obtained by the encoder 23.Accordingly, the tape feed operation of the preceding tape 14(1) and thesubsequent tape 14(2) in the tape feeder 5 is executed. Additionally, anoperation and display panel 26 arranged on an upper surface on theupstream side of the tape feeder 5 is connected to the feeder controller28.

As illustrated in FIG. 5, the operation and display panel 26 is providedwith a tape feed button 26 a, a tape return button 26 b, an operationbutton 26 c, and a notification lamp 26 d. The tape feed operation andtape return operation of the first tape feed mechanism 20A and thesecond tape feed mechanism 20B of the tape feeder 5 can be performed byoperating the tape feed button 26 a and the tape return button 26 b. Theoperation button 26 c performs various kinds of operations, such asselection of the first tape feed mechanism 20A and the second tape feedmechanism 20B, and component ID writing to a built-in memory (refer to afeeder storage unit 36 illustrated in FIG. 6B) of the tape feeder 5. Thenotification lamp 26 d is an LED signal lamp for notification, andperforms notification based on preset predetermined items. Notificationduring the component verification processing of verifying whether or notstored components of the subsequent tape 14(2) subsequently inserted forcomponent replenishment to be described below are correct is included intargets for this notification.

FIG. 5 illustrates component replenishment work for inserting thesubsequent tape 14(2) into the tape feeder 5 in a state where thepreceding tape 14(1) out of the two carrier tapes 14 sent one afteranother is mounted. In this component replenishment work, the workerprepares a supply reel 13 corresponding to stored components serving asreplenishment targets. Then, in order to verify whether or not thestored components of the prepared supply reel 13 are a correct componenttype to be replenished, a bar code label L that is a component ID labelpatched in advance on the supply reel 13 for component typeidentification is read by a bar code reader 16 (component ID readingunit).

The reading result is transmitted to a host system 30 via a wirelessreceiving device 31 (refer to FIGS. 6A and 6B), and is furthertransmitted from the host system to the component mounting apparatus 1.Then, the component verification processing between componentarrangement data 32 b (refer to FIG. 6A) (to be described below)included in production data that the component mounting apparatus 1 hasdownloaded from the host system 30, and a component ID read by the barcode reader 16 is performed. Then, if the read component ID is correct,the component mounting apparatus 1 turns on the notification lamp 26 dof the operation and display panel 26 of the tape feeder into which thesubsequent tape 14(2) is inserted, and visually notifies the fact to theworker. In response to this information, the worker inserts the carriertape 14 pulled out from the prepared supply reel 13 into the tape feeder5 as the subsequent tape 14(2).

Next, the configuration of the component mounting apparatus 1 and acontrol system of the component verification system that verifieswhether or not the stored components of the subsequent tape 14(2)subsequently inserted into the tape feeder 5, in a state where thepreceding tape 14(1) is mounted, for component replenishment in thecomponent mounting apparatus 1 is correct will be described withreference to FIGS. 6A and 6B. In addition, FIG. 6A illustrates theoverall configuration of the component verification system, and FIG. 6Billustrates the configuration of a plurality of the tape feeders 5 to bemounted on the component supply unit 4 of the component mountingapparatus 1 in the component verification system.

In FIG. 6A, the component mounting apparatus 1 is connected to the hostsystem 30 via a LAN system (not illustrated). Various kinds of data,such as production data to be used for the component mounting work inthe component mounting apparatus 1 are stored in a storage unit 30 aprovided in the host system 30. In the component mounting work performedby the component mounting apparatus 1, the production data is downloadedfrom the host system 30 and is stored in the storage unit 32, and theoperation information of the component mounting apparatus 1 is collectedby the host system 30. Additionally, the host system 30 includes thewireless receiving device 31 that receives signals from portableterminals, such as the bar code reader 16.

The apparatus controller 29 is an arithmetic processing unit including aCPU function, and executes a processing program stored in the storageunit 32, thereby controlling respective units of the component mountingmechanism 10, the component supply unit 4, and the display unit 15.During the control processing performed by the apparatus controller 29,various kinds of production data, such as mounting data 32 a, thecomponent arrangement data 32 b, component information 32 c, or thelike, which are downloaded from the host system 30 and stored in thestorage unit 32, are referred to.

The mounting data 32 a is data of the component type of electroniccomponents to be mounted, the mounting position coordinates of thesubstrate, or the like, and is stored for every substrate type that is aproduction target. The component arrangement data 32 b is data thatspecifies the array of the tape feeders 5 in the component supply unit4, that is, data in which the mounting positions of the tape feeders 5and component IDs that are identification information that specifiescomponents set in the tape feeders 5 are made to correspond to eachother in the feeder base 12 a. The component information 32 c is datapeculiar to a component type that specifies a component ID or acomponent size for each component and the details of the tape feedoperation in each tape feeder 5.

The feeder specifying unit 33 specifies the mounting position of a tapefeeder 5 in which the insertion of the subsequent tape 14(2) is detectedby an insertion detecting unit 28 a for the tape feeder 5 to bedescribed below. The component verifying unit 34 performs the processingof verifying whether or not the correspondence relationship between thecomponent ID read by the bar code reader 16 and the tape feeder 5specified by the feeder specifying unit 33, that is, a tape feeder 5into which the insertion of the subsequent tape 14(2) is detected, iscorrect. Accordingly, it is confirmed whether or not the correspondencerelationship between the component ID specified in the componentarrangement data 32 b and the feeder address is correctly observed.

The re-verification requesting unit 35 performs the processing ofrequesting re-execution of the verification processing of the worker ifthe insertion detecting unit 28 a for the tape feeder 5 to be describedbelow detects that the subsequent tape 14(2) has fallen from the tapefeeder 5 after the component verification processing is executed by thecomponent verifying unit 34. That is, when tape falling has beendetected, in order to prevent an occurrence of a work error accompanyingre-insertion as well as the work of re-inserting the fallen subsequenttape 14(2), the worker is forced to perform repetitive execution of thecomponent verification processing. In addition, although a configurationexample in which the component verifying unit 34 and the re-verificationrequesting unit 35 are provided as the processing functions of thecomponent mounting apparatus 1 is illustrated herein, these processingfunctions may be provided as the processing functions of the host system30.

The display unit 15 displays various kinds of screens required for theexecution of the component mounting work by the component mountingapparatus 1. A notification screen that visually displays various kindsof information items in the execution of component verificationprocessing and a work instruction screen are included in these displayscreens (refer to FIG. 10). Accordingly, the display unit 15 is anotification unit that visually notifies the above-mentioned items. Inaddition, as notification means to function as the visual notificationunit, a configuration in which notification contents are transmittedwith blink patterns specified in advance, such as an alarm lamp, may beadopted besides the display unit 15 that displays notification contentson a screen.

In FIG. 6B, the feeder controller 28 controls the first tape feedmechanism 20A and the second tape feed mechanism 20B. This control isperformed based on a control signal from the component mountingapparatus 1, an operation input from the operation and display panel 26,and a signal from the encoder 23 built into the sprocket 21B. The feedercontroller 28 includes the insertion detecting unit 28 a, a tape fallingdetermining unit 28 b, and a tape falling notifying unit 28 c asinternal processing functions. The insertion detecting unit 28 a detectsthat the subsequent tape 14(2) has been inserted into the tape feeder 5based on the rotation detection result of the sprocket 21B by theencoder 23. The tape falling determining unit 28 b determines that thesubsequent tape 14(2) has fallen from the sprocket 21B of the secondtape feed mechanism 20B, similarly based on the rotation detectionresult of the sprocket 21B by the encoder 23.

The insertion detection and the tape falling determination will bedescribed with reference to FIGS. 7A to 7C. FIG. 7A illustrates a statewhere a new subsequent tape 14(2) is introduced via the sprocket 21Cfrom the tape introduction port 5 d and is engaged with the sprocket21B, in a state where the preceding tape 14(1) is already mounted.During the mounting operation of the subsequent tape 14(2), theinsertion detecting unit 28 a monitors the rotation detection signalfrom the encoder 23 that is rotation detecting means, and as illustratedin FIG. 7B, determines that the subsequent tape 14(2) has been insertedfrom the tape introduction port 5 d (arrow f), on the basis that therotation of the sprocket 21B in the normal direction (arrow d) has beendetected.

Accordingly, the encoder 23 and the insertion detecting unit 28 a serveas a tape insertion detecting unit that detects that the subsequent tape14(2) has been inserted into the tape feeder 5. Then, this tapeinsertion detecting unit detects the insertion of a subsequent tape, onthe basis that a sprocket provided in a tape feed mechanism that feedsthe subsequent tape rotates in accordance with the insertion of thesubsequent tape 14(2).

In this tape insertion, although the subsequent tape 14(2) is held bythe sprocket 21C, if a large external force is exerted due to anunsuitable operation or the like of the worker, a holding state cannotbe maintained with only a holding force obtained by the sprocket 21C,and a malfunction in which the subsequent tape 14(2) separates from thesprocket 21B may occur. In the present embodiment, such tape separationis detected by a method to be described below and is notified to theworker.

Namely, during the mounting operation of the subsequent tape 14(2), thetape falling determining unit 28 b monitors the rotation detectionsignal from the encoder 23, and as illustrated in FIG. 7C, determinesthat the carrier tape 14(2), which was once inserted and engaged withthe sprocket 21B, has been disengaged from the sprocket 21B, and movedand separated in the reverse direction (arrow g), on the basis that therotation of the sprocket 21B, which is provided in the second tape feedmechanism 20B that feeds the subsequent tape 14(2), in the reversedirection (arrow e) has been detected. Accordingly, the encoder 23 andthe tape falling determining unit 28 b serve as a tape falling detectingunit that detects that the subsequent tape 14(2) has fallen from thetape feeder 5.

The tape falling notifying unit 28 c notifies the tape fallingdetermined by the tape falling determining unit 28 b to the apparatuscontroller 29 of the component mounting apparatus 1. Then, the apparatuscontroller 29 notifies to the worker that the subsequent tape 14(2) hasfallen, by the notification means, such as the display unit 15 providedin the component mounting apparatus 1. That is, the notification means,such as the tape falling notifying unit 28 c and the display unit 15,serve as a tape falling notifying unit that notifies the fact that it isdetected that the subsequent tape 14(2) has fallen.

Next, a component supply method in the component mounting apparatus 1will be described with reference to FIGS. 8A to 8C and FIGS. 9A to 9C.This component supply is performed by sequentially feeding the pluralityof carrier tapes 14 through the splicingless method in the tape feeder5. FIGS. 8A to 8C and FIGS. 9A to 9C illustrate the process of feedingthe preceding tape 14(1) sent precedingly and the subsequent tape 14(2)sent subsequently along the tape traveling path 5 c out of the twocarrier tapes 14 sent one after another.

First, FIG. 8A illustrates a state where the component mounting work isbeing executed while feeding the preceding tape 14(1) along the tapetraveling path 5 c. Namely, the preceding tape 14(1) is introduced intothe tape feeder 5 via the tape introduction port 5 d and is pitch-fed(arrow w) to the component suction positions by the first tape feedmechanism 20A (first tape feed process), and electronic components aretaken out from the preceding tape 14(1) by the mounting head 9 at thecomponent suction positions.

Next, if the supply of the components from the preceding tape 14(1)approaches the end in the process of continuously executing thecomponent mounting work, as illustrated in FIG. 8B, the subsequent tape14(2) is added and set for component replenishment. Namely, a leadingportion of the subsequent tape 14(2) is introduced (arrow X) via thesprocket 21C disposed at the tape introduction port 5 d and is insertedbetween the sprocket 21B and the preceding tape 14(1), in a state wherethe preceding tape 14(1) is engaged with the sprocket 21B of the secondtape feed mechanism 20B by the tape pressing mechanism 24.

If the insertion of the subsequent tape 14(2) is detected, as the secondtape feed mechanism 20B is driven, the subsequent tape 14(2) engagedwith the sprocket 21B is sent to the downstream side, and the leadingend portion T of the subsequent tape 14(2) abuts against and is stoppedby the stopper member 25 a of the tape stopper mechanism 25. That is, ifthe insertion of the subsequent tape 14(2) is detected, the sprocket 21Brotates by a predetermined amount, and pitch-feeds the subsequent tape14(2) until the subsequent tape abuts against the stopper member 25 a.Then, in this state, the subsequent tape 14(2) stands by, and the pitchfeeding of the preceding tape 14(1) by the first tape feed mechanism 20Aand the extraction of the electronic components by the mounting head 9continue being executed.

Thereafter, in the middle of the feeding of the preceding tape 14(1), asillustrated in FIG. 8C, the trailing end portion E of the preceding tape14(1) is detected by the second sensor S2, and the detection result istransmitted to the feeder controller 28 (refer to FIGS. 6A and 6B).Then, the feeder controller 28 controls the first tape feed mechanism20A and the second tape feed mechanism 20B based on a preset controlpattern.

Namely, if the trailing end portion E of the preceding tape 14(1) hasbeen detected by the second sensor S2, the second tape feed mechanism20B is driven to move the subsequent tape 14(2) in a state where thetemporary stop performed by the stopper member 25 a is already releasedso that the leading end portion T reaches the second detection positionP2. Then, as illustrated in FIG. 9A, if the leading end portion T of thesubsequent tape 14(2) is detected by the second sensor S2, the secondtape feed mechanism 20B is stopped, and the subsequent tape 14(2) ismade to stand by at this position. Then, in this state, the pitchfeeding of the preceding tape 14(1) by the first tape feed mechanism 20Aand the extraction of the electronic components by the mounting head 9continue being executed.

Moreover, if the trailing end portion E of the preceding tape 14(1) hasbeen detected by the first sensor S1 as illustrated in FIG. 9B in theprocess of performing the pitch-feed of the preceding tape 14(1) by thefirst tape feed mechanism 20A, as illustrated in FIG. 9C, the subsequenttape 14(2) is fed in order to drive the second tape feed mechanism 20Bto move the leading end portion T of the subsequent tape 14(2) from thesecond detection position P2 to the first detection position P1. Alongwith this, the preceding tape 14(1) that has ended the component supplyis discharged from the tape feeder 5.

Next, the component verification processing of verifying whether or notthe stored components of the subsequent tape 14(2) subsequently insertedinto the tape feeder 5, in a state where the preceding tape 14(1) ismounted, for component replenishment are correct will be describedreferring to FIGS. 12A to 12C and respective drawings according to theflow of FIGS. 10 and 11.

First, reading of a component ID is performed (Step ST1), and acomponent ID corresponding to the stored components of the subsequenttape 14(2) are read (component ID reading process). That is, asillustrated in FIG. 5, the worker prepares a new supply reel 13 forreplenishment for a tape feeder 5 that requires component replenishment,and operates the bar code reader 16 to read a bar code label L patchedon the supply reel 13. The reading result is transmitted to thecomponent mounting apparatus 1 via the host system 30 through wirelesscommunication.

The component verifying unit 34 confirms whether or not there is a tapefeeder 5 corresponding to the read component ID, with reference to themounting data 32 a and the component arrangement data 32 b (Step ST2).Here, if it is determined that there is no corresponding tape feeder,error notification is performed (Step ST3). That is, as illustrated inFIG. 12A, a message showing “there is no tape feeder into which a tapehaving the read component ID is to be inserted” is displayed on thenotification screen 15 a.

When the component ID read in the component ID reading process iscorrect and there is a corresponding tape feeder in Step ST2, visualnotification for specifying a tape feeder 5 is performed (Step ST4).Here, it is visually notified that the tape feeder 5 is thecorresponding tape feeder 5 by turning on the notification lamp 26 dprovided at the operation and display panel 26 of the corresponding tapefeeder 5. Next, insertion of a carrier tape 14 is performed (Step ST5).That is, the worker inserts the subsequent tape 14(2) serving as areading target into the tape feeder 5 serving as a notification targetin Step ST4. Next, carrier tape insertion detection is performed (StepST6). That is, as the subsequent tape 14(2) is inserted into the tapefeeder 5, the sprocket 21B of the second tape feed mechanism 20Brotates, and the insertion detecting unit 28 a detects the subsequenttape insertion based on the fact that the encoder 23 detects thisrotation (tape insertion detecting process).

Next, a tape feeder into which the carrier tape is inserted is specified(Step ST7). That is, by detecting a tape feeder in which tape insertionis detected, the feeder specifying unit 33 specifies the mountingposition of the tape feeder in which the insertion of the subsequenttape 14(2) is detected (feeder specifying process). Next, it is verifiedwhether or not the correspondence relationship between the tape feederspecified in this feeder specifying process and the read component ID iscorrect (Step ST8). That is, the component verifying unit 34 verifieswhether or not the correspondence relationship between the readcomponent ID 36 a and the mounting position of the specified tape feederis correct, by referring to the component arrangement data 32 b(component verifying process).

Here, when the correspondence relationship is not correct, that is, whentape insertion is performed on a tape feeder 5 on which tape insertionshould not be performed, error notification is performed (Step ST9). Inthis error notification, the fact is visually notified to the displayunit 15 that is the notification unit. That is, as illustrated in FIG.12B, a message 15 c showing “a tape feeder into which a tape is insertedis not correct” is displayed on the notification screen 15 a.Additionally, when the correspondence relationship between the componentID and the mounting position of the tape feeder is determined to becorrect in Step ST8, it is determined that the component verificationhas been normally performed and component information writing isperformed (Step ST10). That is, the component ID 36 a is written in thefeeder storage unit 36.

FIG. 11 illustrates component verification processing in tape fallingexecuted when the subsequent tape 14(2) in the state of being onceinserted into a tape feeder 5 has fallen from the tape feeder 5, due toa certain cause, such as a worker's carelessness, after theabove-described component verification processing is ended. Here, first,the respective steps (Step ST1 to Step ST10) illustrated in the flow ofFIG. 10 are completed, and a processing step begins from the state ofcomponent verification processing completion (Step ST20) where thecomponent ID 36 a is written.

That is, if tape falling occurs after this, the tape falling isdetermined by the tape falling determining unit 28 b that has received arotation signal from the encoder 23, and the fact is notified to thecomponent mounting apparatus 1 by the tape falling notifying unit 28 c.In the component mounting apparatus 1 that has received thisnotification, it is determined that it is detected that the subsequenttape 14(2) has fallen from the tape feeder (Step ST21) after thecomponent verifying process, the tape falling notification (Step ST22)(tape falling notification process) of notifying the fact is performed,and the re-verification request (Step ST23) of requesting re-executionof the component verification processing illustrated in the flow of FIG.10 to the worker is performed (re-verification requesting process).

That is, in the display unit 15, as illustrated in FIG. 12C, a tapefalling notification message 15 d showing that “tape falling has beendetected”, and a re-verification request message 15 e showing “Pleaseexecute the component verification work again” are displayed on thenotification screen 15 a. Then, the worker who has received thisre-verification request executes the re-verification processing ofrepeating the processing illustrated in the flow of FIG. 10 (Step ST24).Then, the fallen subsequent tape 14(2) is re-inserted into the tapefeeder 5 after the re-verification processing execution. In this case,the data processing of eliminating the component ID 36 a, which was oncewritten in the feeder storage unit 36, is performed (Step ST25).Accordingly, a malfunction caused by wrong component ID being stored andremained as it is can be avoided.

Next, whether or not the re-verification execution has been confirmed isdetermined through the processing history of the component verifyingunit 34 (Step ST25). Here, if the re-verification execution has beenconfirmed, it is determined that the component verification processinghas been normally executed, and the component information writing isperformed again (Step ST26). Additionally, when the re-verificationprocessing execution is not confirmed, the processing returns to StepST23 and the re-verification request is continued. Then, finally, as there-verification processing execution is confirmed through in Step ST26,the component verification processing in tape falling is ended.

As described above, in the present embodiment, in the componentverification processing of verifying whether or not the storedcomponents of the subsequent tape 14(2) subsequently inserted into thetape feeder 5, in a state where the preceding tape 14(1) is mounted, forcomponent replenishment are correct, an artificial operation errorproduced when the worker inserts the subsequent tape 14(2) can beeliminated by reading the component ID corresponding to the storedcomponents of the subsequent tape 14(2) and detecting that thesubsequent tape 14(2) has been inserted into the tape feeder 5, therebyspecifying a tape feeder 5 serving as a component verification target,and verifying whether or not the correspondence relationship between theread component ID and the specified tape feeder 5 is correct.Additionally, if it is detected that the subsequent tape 14(2) hasfallen from the tape feeder 5 after the component verification, amalfunction resulting from a work error in re-mounting of the fallensubsequent tape 14(2) can be prevented by requesting re-execution of theverification to the worker.

The component verification method and the component verification systemof the invention have an effect in which malfunctions resulting from awork error in re-mounting of a fallen subsequent tape can be prevented,and are useful in a component mounting field in which electroniccomponents are taken out from a tape feeder, and are mounted to asubstrate.

What is claimed is:
 1. A component verification method for verifyingwhether or not a stored component of a subsequent tape subsequentlyinserted into a tape feeder, in a state where a preceding tapeprecedingly sent out of two carrier tapes sequentially sent one afteranother is set, for component replenishment is correct, in a componentmounting apparatus that picks up components, which are supplied fromcarrier tapes tape-fed by a plurality of tape feeders arrayed in acomponent supply unit, by a mounting head to mount the components on asubstrate, the component verification method comprising: a component IDreading process of reading a component ID corresponding to the storedcomponent of the subsequent tape; a tape insertion detecting process ofdetecting that the subsequent tape has been inserted into the tapefeeder; a feeder specifying process of specifying a tape feeder in whichthe insertion of the subsequent tape has been detected; a componentverifying process of verifying whether or not a correspondencerelationship between the read component ID and the specified tape feederis correct; and a re-verification requesting process of requestingre-execution of the verification to a worker if it is detected that thesubsequent tape has fallen from the tape feeder after the componentverifying process.
 2. The component verification method according toclaim 1, further comprising a tape falling notification process ofnotifying, when it is detected that the subsequent tape has fallen, afact to that effect.
 3. The component verification method according toclaim 1, wherein in the tape insertion detecting process, the subsequenttape insertion is detected by a fact that a sprocket provided in atape-feed mechanism that tape-feeds the subsequent tape rotates inaccordance with the insertion of the subsequent tape.
 4. A componentverification system for verifying whether or not stored components of asubsequent tape subsequently inserted into a tape feeder, in a statewhere a preceding tape precedingly sent out of two carrier tapessequentially sent one after another is mounted, for componentreplenishment is correct, in a component mounting apparatus that picksup components, which are supplied from carrier tapes tape-fed by aplurality of tape feeders arrayed in a component supply unit, by amounting head to mount the components on a substrate, the componentverification system comprising: a component ID reading unit that reads acomponent ID corresponding to the stored component of the subsequenttape; a tape insertion detecting unit that detects that the subsequenttape has been inserted into the tape feeder; a feeder specifying unitthat specifies a tape feeder in which the insertion of the subsequenttape has been detected; a component verifying unit that verifies whetheror not a correspondence relationship between the read component ID andthe specified tape feeder is correct; and a re-verification requestingunit that requests re-execution of the verification to a worker if it isdetected that the subsequent tape has fallen from the tape feeder afterthe verification.
 5. The component verification system according toclaim 4, further comprising a tape falling notification unit thatnotifies, when it is detected that the subsequent tape has fallen, afact to that effect.
 6. The component verification system according toclaim 4, wherein the tape insertion detecting unit detects thesubsequent tape insertion by a fact that a sprocket provided in atape-feed mechanism that tape-feeds the subsequent tape rotates inaccordance with the insertion of the subsequent tape.